Sustainable Energy Management Program in SOEM-KL

ASEAN Best Practices Competition for Energy Management
in Building and Industries

ASEAN Energy Awards 2014
SUSTAINABLE ENERGY MANAGEMENT PROGRAM

IMPLEMENTATION IN
SONY EMCS (MALAYSIA) SDN. BHD. KL TEC

2. Certification and Endorsement

__________________________________________________________________
The Sony EMCS (Malaysia) Sdn Bhd KL Tec hereby agreed to allow the ACE Board of
Judges and the Japanese experts to visit the building and verify the authenticity of the data.
However, two weeks advance notice is required to allow for necessary arrangements.
We also hereby agreed that ACE can publish the whole submission in ACE publications and
website, without any prior consent of the owner of the buildings amd industries (factories). If the
submission will be published in other publications, the consent of the concerned buildings and
industries (factories) would require.
The undersigned certified that the information given is true and accurate and prepared with the
consent of the party/ies involved.
______________________
Yoshihiro Kuriyama
Sony EMCS (Malaysia) Sdn Bhd KL Tec,
KL Tec President
Tel: 603-89283701; Fax: 603-89221178l
E-mail: Yoshihiro.Kuriyama@ap.sony.com
______________________
Kamarul Azman Dimin
Sony EMCS (Malaysia) Sdn Bhd KL Tec,
Assistant General Manager
Tel: 603-89297212; Fax: 603-89297146
E-mail: Kamarulazman.Dimin@ap.sony.com
_______________________
Endorsed by Focal Point
Datuk Loo Took Gee,
Secretary General
Ministry of Energy, Green Technology and Water,
Malaysia
Tel: 603 8889 3711; Fax:603 8889 3177
E-mail: LooTG@kettha.gov.my
2

3. Project/Activity overview
3.1
Description
Sony EMCS (Malaysia) Sdn. Bhd KL Tec (SOEM KL)
is established in 1988 with a paid-up capital investment
of 35 million Malaysian Ringgit (RM). SOEM KL is part
of Sony Corporation Group which is one of the leading
manufacturers of electronics products for the consumer
and professional markets. SOEM KL produces LCD
television, Blu-ray disc player/recorder, and tuner.
SOEM KL is located at Bandar Baru Bangi, Selangor,
Malaysia with a build-up area of 83,101 m2 and total
employees of 6,269 (as of March 2015). Figure 2
shows SOEM KL electricity consumption by functional areas
in fiscal year (FY) 2014.
Figure 2: SOEM KL FY2014 electricity consumption by area
Figure 1: SOEM KL (Malaysia) Sdn. Bhd
Figure 3: SOEM KL electricity consumption FY2007 to FY2014
3.2
Rationale
SOEM KL energy demand is on the rise (see Figure 3). This is a critical reality for
SOEM KL; as the company grows, production increase and requirements for machineries
and equipment increase. Energy price is also expected to increase with time; with the
latest electricity tariff hike of 17% already taken place in January 2014. Furthermore,
measures to reduce energy consumption can help to mitigate global warming impact due
to fossil fuel burning. SOEM KL energy mix is solely come from electricity. SOEM KL
expenses for electricity consumption increased from RM14.2 million in FY2008 to
RM16.1 million in FY2010.
3.3
Target
According to Sony Green Management 2015 that serves as a yardstick for the
environmental activities of Sony Group worldwide until FY2015, SOEM KL is required
to reduce electricity consumption (calculated by CO2 emission reduction) by 14%, using
FY2008 as the baseline. This comes to 2% reduction per year (see Figure 4).

Actual + plan
Reduction
Accum. Reduction (%)
Energy Usage (Ton CO2)
25,900
25,000 23,700
20,000
23,100
22,184
23,400
22,700
21,400
25,000
34
15,900
16,864
70
60
19,250
17,800
21,677
15,000
16,895
50
17,000
40
30
10,000
5,000
20,80053
80
69
65
5,500
1,516
0 0
FY2008 Base
FY2009
3 900
20
3,936
2,355
1,023
800
10
Improvement Ratio (%)
Projection
30,000
FY2010
FY2011
FY2012
FY2013
FY2014
FY2015
Figure 4: SOEM KL Mid-Range Plan Target for CO2 Emission Reduction
SOEM KL would also like to improve on its Energy Management Matrix to Level 3
upwards. Based on the Energy Management Matrix in Figure 5, previously there was:
no energy policy
energy management is part time
responsibility
informal contacts between engineer
and a few users
cost reporting based on invoice data
informal contacts used to promote
energy efficiency
same payback criteria employed as for
other investment
After Sustainability Energy Management
Programmes implementation in FY2011,
the energy management components have
improved as indicated by blue line in
Figure 5.
Figure 5: SOEM KL Energy Management Matrix

4. Impact
______________________________________________________________________________
4.1
Energy Saving
With SEMP in place, SOEM KL electricity consumption shows a reducing trend from
FY2010 to FY2014 (see Figure 6). In this write-up, FY2010 figures will be used as the
baseline indicator to measure the progress of SOEM KL energy saving measures.
Through various energy saving measures below, SOEM KL electricity consumption had
reduced by 14% in FY2011, 36% in FY2012, and 33% in FY2013 respectively, even
though with expansion of operations and increased in production outputs (see Table 1).
6
5
5.1
4.7
4.6 4.7 4.6
4
4 4.1
4.3
4.6 4.54.5
Electricity
Consumption
(kWh)
%
Saving
in kWh
Electricity
Cost (RM)
%
Saving
in RM
2010
56,112,584
N/A
16,079,965
N/A
2011
48,212,226
14%
14,989,483
7%
2012
35,692,730
36%
11,606,725
28%
2013
37,362,475
33%
12,544,108
22%
2014
37,627,488
33%
14,171,403
12%
3.9
3.53.53.5
3.2 3.3 3.2 3.1 3.3
3.0
3.4
3.2 3.2
2.9
3.03.13.13.1
3 3.1
3.33.3
2.9
2.6 2.7
3.2
3.1
2.8
2.3
Figure 6: SOEM KL electricity consumption in FY2010 to FY2014

Measures
Delamping
Compressed air leakage reduction
Eco Challenge
Translucent roof installation
Replaced magnetic ballast with electronic ballast
LED lights installation
Total FY2011
Building Management System for air-conditioning
Cool air leakage reduction
Eco Challenge
Solar street light installation
VSD air compressor installation
Chiller installation
Total FY2012
Compressed air leakage reduction
Delamping
Reschedule AHU during weekend/non working day
Increase centralised air-condition temperature
Reduce 2nd chiller operation time
Compressor shutdown during weekend
Clean booth FFU shutdown during weekend
Clean booth FFU speed reduction
LCD production total power shutdown during weekend
Oven cooling mode temperature reduction
LEV optimisation
Auto Mount PC optimisation
Reflow oven insulation
LCD K-Box conveyor-less operation
VSD air compressor installation
Total FY2013
Savings
CO2 (ton)
115
1212
586
63
30
790
2,796
1469
118
1263
13
165
4,766
7,794
143
101
1817
115
376
56
50
121
146
247
345
48
260
627
177
165
4,794
kWh
153,585
1,622,101
784,046
84,548
67,416
1,057,425
3,769,121
1,966,094
157,303
1,691,249
17,136
221,184
6,380,000
10,432,966
191,540
134,729
2,432,000
153,560
504,000
74,880
67,595
161,741
195,538
331,200
461,713
64,632
348,333
839,793
237,000
221,184
6,419,438
Feb
Oct
Dec
Aug
Apr
Jun
Feb
Oct
Dec
Aug
Apr
Jun
Feb
Oct
Dec
Aug
Apr
Jun
Feb
Oct
Dec
Aug
Apr
Year
4.24.2 4.3
Jun
Monthly Usage (kWh x million)
5.1
4.84.8 4.7 4.8
Table 1: SOEM KL Energy Savings vs. FY2010
RM
38,400
350,200
244,100
19,000
16,854
264,400
932,954
491,500
39,300
585,400
4,284
55,296
1,900,000
3,075,780
47,900
40,400
608,00
46,100
151,200
22,500
20,300
48,500
58,700
99,400
138,500
19,400
104,500
251,900
13,066,355
66,355
14,182,010
Investment
RM
40,000
74,000
235,000
500,100
849,100
33,400
202,000
203,000
432,500
11,600,000
12,470,900
74,000
215,500
280,000
477,500
1,047,000
Table 2: SOEM KL energy saving measures achievement FY2011 to FY2013
Payback period
Year
0.2
3.9
13.9
1.9
0.9
0.8
0.3
47.4
7.8
6.1
4.1
0.7
0.9
0.02
7.2
0.1

The implemented energy saving measures were segregated into zero investment projects
and with-investment projects with their gained savings is shown in Table 3.
4.2
Environmental Effect
Green Management 2015 focuses on four key environmental perspectives curbing
climate change, resource conservation, controlling chemical substances and promoting
biodiversity. At present, every Sony product negatively affects the environment to some
degree throughout its life cycle thereof. To ensure Sony ability not only to conduct its
business in a responsible manner, but also to take responsibility for the environmental
impact of every Sony product at each stage of its lifecycle, Sony have divided the product
lifecycle into six stages: research and development, product planning and design,
procurement, operations, logistics, and take back and recycling.
SOEM KL operations are directly related with three stages: product planning and design,
operations and logistics.
Product Planning and Design Activities
Perspective
Climate
change
Resource
Chemical
Target
Achievement
(as of FY2013)
Reduce annual energy

consumption of products by 30%
43%
Reduce utilisation ratio of virgin oilbased plastic in products by 5%
44%
Reduce mass of products by 10%
35%
Eliminate Class 1 chemical usage

in products
Complied for
BVR & PVC
Table 3: Design activities targets
1. Reduce virgin material usage

Incorporated post consumer PET bottle in
BDP 9G players design. Total recycle
material usage was at 76%.
ABS+PET
Virgin
Recycle
2. Reduce product weight

With the set width reduction of 25m,
its weight had been reduced by 21%.
290 mm
BDP-S6200
30%
8G BDP (BDP-S1100 & BDP-S3100) - 1,030g
Side panel: 35 g
PC
Virgin
Recycle
265 mm
Total plastic: 535g
40%
Main panel: 264 g
USB cover: 1 g
Button: 2 g
Figure 8: Reduction in weight for BDP 9G
All model
PS
Virgin
9G BDP (BDP-S1200, BDP-S3200 & BDP-S4200) 818g
Recycle
65%
Loading mecha: 107 g
Figure 7: Recycle material content in BDP 9G

Logistics activities
Perspective
Achievement
(as of FY2013)
Target
Climate
change
Resource
Reduce GHG emission by 10%
33%
Reduce incoming parts packaging

waste by 16%
68&
Table 4: Logistics activities targets
EPS packaging
1. Reduce emission from transportation

By changing TV K-Box packaging from EPS
packaging to nesting packaging & by implementing
horizontal loading (see Figure 9), the Container
Loading Efficiency had improved by 13%, thus
reducing 263 units of Forty feet Equivalent Unit (FEU)
required for transportation . Hence, the CO2 emission due
product transportation was reduced by 20 tons.
Vertical loading
Nesting packaging
Horizontal loading
Operations activities
Perspective
Climate
change
Resource
Achievement
(as of FY2013)
Target
Reduce GHG emission by 14%
50%
Reduce waste generation by 28%
80%
Reduce water consumption by

14%
16%
Reduce amount of VOC release to

air by 28%
Chemical
Biodiversity
Promote environmental activity

within local community
Figure 9: Container Loading Efficiency improvement
146%
Tree planting,
school projects
Table 5: Operations activities targets
Using 2011 Malaysia CDM baseline emission factor of 0.000747 ton CO2/kWh, Table 6
shows the SOEM KL carbon emission for FY2010 to FY2014. SOEM KL had managed
to reduce its carbon emission by 13,808 ton CO2 with the implementation of all energy
saving measures listed above.
Year
Energy
Consumption (kWh)
CO2 Emission
(ton)
% Saving
2010
56,112,584
41,916
N/A
2011
48,212,226
36,015
14%
2012
35,692,730
26,662
36%
2013
37,362,475
27,910
33%
2014
37,627,488
28,108
33%
Table 6: Carbon emission for FY2010 to FY2014
Pulp cushion
Carton waste
Carton
1. Waste recycling
SOEM KL had implemented closed loop carton and paper
waste recycling since FY2009. All carton and paper from
7
Figure 10: Closed loop carbon waste recycling

incoming parts packaging wastes are sent to recycler. The recycler will processes these
carton and paper wastes into pulp cushion and carton, which will be used back in SOEM
KL as products packaging (see Figure 10). Until FY2013, SOEM KL had successfully
reduced 13,301 tonnes of waste with this activity.
2. Volatile Organic Compound (VOC) reduction
Through Printed Wiring Boards design change, the use of wave soldering machines were
replaced with spot dip machines. This enabled SOEM KL to reduce the amount of VOC
used in its soldering operation through lesser usage of flux and thinner. Total VOC
reduction saving due to this activity was 57 tonnes.
4.3
Economic Effect
4.3.1 Investment
Energy efficiency and energy conservation investments are given the same consideration
as for all other investments by SOEM KL Top Management. Generally, all investment
will be appraised using the Simple Payback Period (see Figure 11).
SPP = Total amount of investment / Annual saving
Investment with
payback less
than 1 year
Zero investment
Investment with
payback within 3
years
Investment with
payback more
than 3 years
Figure 11: SOEM KL investment consideration
However, operational and safety consideration may sometime carry more weight than the
above financial consideration alone.
4.3.2
Payback period
Table 7 below shows SOEM KL investment for energy saving measures for FY2011 to
FY2014 and their payback period.
Year
Investment
(RM)
Cost saving
( RM)
Payback period
(Year)
2011
849,100
932,954
0.9
2012
12,470,900
3,075,780
4.1
2013
1,047,000
14,182,010
0.1
2014
1,040,481
975,000
1.1
Table 7: SOEM KL investment and payback for FY2011 to FY2014
From the investment, SOEM KL had saved RM933,000 in FY2011, RM3.1 million in
FY2012, RM14.2 million in FY2013 and RM0.975 Million in FY2014.. Total payback
period was 0.9 year for FY2011, 4.1 year for FY2012, 0.1 year for FY2013, and 1.1 year
for FY2014 respectively.

4.4
Energy Efficiency Index (EEI)

EEI is used to track the performance of energy consumption. SOEM KL uses the
following formula to calculate its EEI:
EEI
kWh
Production Quantity
In FY2010, SOEM KL EEI was 5.1 kWh/ unit. SOEM KL had achieved EEI of 4.3 in
FY2011 i.e. 16% reduction, 3.3 in FY2012 i.e. 35% reduction, 2.6 in FY2013 i.e. 49%
reduction and 2.9 in FY2014 i.e. reduction of 43% (see Table 8).
Year
Energy Consumption
(kWh)
Production Quantity
(unit)
Energy Efficiency
Index
2010
(baseline)
56,112,584
11,096,238
5.1
2011
48,212,226
11,294,000
4.3
2012
35,692,730
10,920,600
3.3
2013
37,362,475
14,197,000
2.6
2014
37,627,488
13,101,200
2.9
Table 8: Energy Efficiency Index

5. Sustainability
SOEM KL strives to ensure that its energy management measures are sustainable through
involvement from all levels, support from top management and short and long term planning as
well as continuous monitoring and improvement.
5.1
Level of Participant and Involvement

SOEM KL SEMP involves the participation of all level of its employees. The Managing
Directors support was evidenced through the SEMPs investments and budget allocation.
His strong commitment was then translated into pledge to save energy during energy
saving project kick-off (see Figure 12). He was also responsible to establish an energy
management committee to oversee the whole companys energy saving programmes.
Management lines involvement is through nightly BBGG genba where every energy
wastage in the company would be highlighted and action needs to be taken immediately
the next day.
Other employees involvement could be seen through their participation in various
projects such as Eco Challenge project, Gold Quest project and Energy Saving project.
For non-project members, they still could contribute ideas for energy saving through Eco
Challenge Idea Box (see Figure 13).
In FY2013, three energy saving awareness roadshows have been conducted. A total of
295 employees participated in various activities during the events (see Figure 14).
According to the surveys conducted in February 2014, 84% of the employees are aware
with the on-going energy saving measures taken place in the company and the reason for
implementing them.
Figure 12: Managing Director pledge for

energy saving
5.2
Figure 13: Ideas are collected

on ways to save electricity
Figure 14: Energy saving quiz and

awareness survey during roadshow
Top Level Management Commitment

SOEM KL SEMP has been achieved by the cooperation of the top
management. A written energy policy has been endorsed by the KL
Tec President, and communicated throughout the company (see
Figure 15).
All SOEM KL energy measures received strong involvement from the
top management, lead by the Managing Director himself. Figure 16
and Figure 17 shows the top management commitment in various
energy saving measures.
10
Figure15: SOEM KL Energy Policy

Figure16: Monthly energy audit at

Production led by Managing Director
5.3
Figure17: FY2013 Energy Saving project

closing
Short and Long-Term Plan

SOEM KL FY2014 energy saving target is to reduce electricity consumption by 5.2
million kWh compared to FY2013. The immediate goals are to reduce energy wastage in
all functional areas by improving maintenance, manufacturing operations and purchasing
high efficient equipment.
Measures
Phase 1 : 4Q FY2013
Zero investment activities
Energy saving promotion & awareness
Total 4Q FY2013
Phase 2: 1H FY2014
Install real-time measurement system at pilot line
Auto Mount Oven insulation
LED lights installation at Auto Mount
Add inverter to AHU (LCD)
Total 1H FY2014
Phase 3: 2H FY2014
Horizontal expansion of real-time measurement system
Oven insulation at Video & Tuner
LED lights installation at Video & common
LED street light installation
Add inverter to AHU (Auto Mount)
Add inverter to exhaust motors
Total 2H FY2014
Phase 4: FY2015
Chiller installation at North Plant
Total Building Management System installation
Total FY2015
kWh
Saving
CO2 (ton)
RM
Investment
RM
Payback period
Year
4,773,128
4,773,128
3,565
3,565
692,600
7,000
692,607
66,667
753,333
500,000
873,333
400,000
2,593,333
50
563
374
652
299
1,938
20,000
226,000
150,000
262,000
120,000
778,000
67,000
168,000
136,000
76,000
200,000
647,000
3.4
0.7
0.9
0.3
1.7
0.8
200,000
300,000
70,000
184,667
613,333
193,333
1,561,333
149
224
52
138
458
144
1,165
60,000
90,000
21,000
55,400
184,000
58,000
468,400
276,000
90,000
23,000
98,000
400,000
121,000
1,008,000
4.6
1
1.1
1.8
2.2
2.1
2.2
4,000,000
667,667
4,667,667
2,988
499
3,487
1,200,000
200,000
1,400,000
4,500,000
667,000
5,167,000
3.8
3.3
3.7
Table 9: SOEM KL energy saving plan
For long-term plan, SOEM KL is now working toward a four-star Green Star assessment
rating (refer Figure 18), signifying that it had met mid-term targets. Progress is evaluated
according to some 230 qualitative assessment criteria.
Quantitative
Chemical
Substances
(Class 3)
Chemical
Substances
(VOC)
Resources (Water)
Qualitative
Greenhouse
4 Gasses
3
2
1
0
Resources
(Waste)
Biodiversity
Resources
(Waste
Recycling
Rate)
Chemical
S b
Greenhouse
4
Gasses
3
2
1
0
Resources
(Waste)
Resources
(Water)
Figure 18: SOEM KL Green Star assessment rating for FY2013 reduction targets
11

Ultimately, as part of Sony Group, SOEM KL has its Road to Zero plan; Sonys global
environmental plan which is to achieve zero environmental footprint throughout the
lifecycle of our products and business activities by FY2050.
5.3.1
Organisation Structure
SOEM KL revamped its Energy Management approach in FY2011, focusing on how to
increase the energy efficiency within its operations by the operations members
themselves. Energy saving was no longer facility departments responsibility only.
Figure 19 shows the SOEM KL Energy Management Committee structure which is made
up from KL Tec President and representatives from energy-related functional areas.
Chairman
KL Tec President
Energy Manager
Reg. Control
Production
Engineering
Design
Plant
Maintenance
Figure 19: SOEM KL Energy Management Committee
Figure 20: Energy Saving Project team
5.3.2
Establishment of Organisation of Energy Management

SOEM KL Energy Saving Project organisation is comprised of three levels: KL Tec
President as the project manager, Division Heads as project leader and team owner, and
Team Leader as the working team to implement the energy efficiency and energy
conservation measures throughout the company operations (see Figure 20).
The Team Leaders hold a meeting everyday to oversee projects progress against the
established targets. They will analyse the electricity usage by each plant and discuss the
reason for the increase or decrease. In the meeting, they also discuss the potential energy
saving measures to be implemented. The proposal for energy saving measures in each
area would be brought to the weekly Top Management Sanction Meeting by the related
Division Head for budget approval.
The promotional team is responsible to promote energy saving culture to all employees
by creating awareness, mind-set change and ownership taking.
5.4
Capacity Building
To ensure the continuity of energy conservation measures, SOEM KL introduced various
new activities to complement the existing ones. The engagement of all employees and
commitment from top management is important for the programmes success.
5.4.1
Activities
Nightly Back to Basic, Go to Genba (BBGG) inspection by top management.
Monthly energy saving audit by top management (see Figure 16).
Road to Zero awareness programme through banners, posters and E-Learning.
12

Set up environmental corner & energy saving booths to promote SOEM KL

environmental activities to all employees (see Figure 24).
Annual environmental campaign with activities such as exhibitions, awareness talk,
quizzes and puzzles.
Adopting Malaysian Standard MS 1525:2001 Code of Practice on Energy
Efficiency as company policy.
Participated in Gold Quest projects utilising value-added analysis approach.
Conducting energy saving awareness campaign through roadshow, daily email and
company intranet (see Figure 14 and Figure 25).
Adopted ASHRAE 55:2010 for comfort temperature setting for air-conditioning
system.
Figure 24: Energy saving promotion through Environmental Corner, notice boards, banners Figure 25: Daily energy awareness
communication
5.4.2
Educational Training
Induction training on environmental awareness for all new employees.
Internal training for energy saving projects members.
External techical trainings for projectss members.
Attended Energy Manager training course under ASEAN Energy Management
Scheme (AEMAS).
Attended energy related workshops organised by governmental bodies.
Visited Malaysia GreenTech and Suruhanjaya Tenaga to learn about their Green
Building practices.
Best practices sharing during annual Pan Asian Sony Environmental Conference.
Visited Japan to learn about energy saving best practices from other Sony
companies.
Nine months consultation by Sony Headquarters team during FY2013 Energy
Saving Project.
13

6. Replicability
__________________________________________________________________
6.1
Management Practices and Measures

SOEM KL is committed to practice energy efficiency
and energy conservation in its operations in order to
create a sustainable working environment. SOEM KL
Energy Management System was developed based on
AEMAS Sustainable Energy Management Programme
(SEMP). The practices are outlined in SOEM KL
SEMP roadmap (see Figure 26).
SOEM KL SEMP has enabled the establishment of
Figure 26: SOEM KL SEMP Roadmap
measurable energy reduction targets and Energy
Efficiency Index without compromising quality, reliability, comfort and safety.
SOEM KL Energy Management approach.
1. Energy audit and target setting
The purpose is to assess building energy efficiency to identify a list of energy saving
measures. It provides a comprehensive analysis of the facility, a breakdown of the energy
use and estimates of implementation cost, potential operating cost savings, and simple
payback periods of the energy saving measures selected to improve the existing
installation.
2. Implementation and operation
The selected energy saving measures will be implemented by project teams. Training is
provided to equip members with the skills and knowledge to properly manage and
maintain equipment, to identify energy savings opportunities, and to implement
operational changes. This would enable them to take ownership of the energy saving
project. This sense of ownership often turns them into energy champion' - always on the
lookout for new ways to improve efficiency and save energy.
3. Analysis and reporting
Detailed analysis of the data is needed to meaningfully report on achieved savings and to
properly demonstrate opportunities for energy conservation. Presenting top management
with compelling energy information encourages team members to take action and is an
effective way of demonstrating the results of energy saving initiatives. Finally,
continuously monitoring and reporting on energy use helps to support a culture of
continuous improvement.
6.2
Technology
Measure 1: Chiller air conditioning system installation.
Methodology: SOEM KL previous air conditioning systems consisted of 51 units of
Water Cooled Package Unit (WCPU) with lifespan between 10 to 22 years old. Their
performance and efficiency deteriorated with age, and with it, increased their
maintenance costs. We estimated the WCPU system efficiency (COP) at 1.18 kW/RT at
the time of replacement.
14

With the installation of new chillers with COP of 6.2 kW/RT, SOEM KL saved about
5,800,000 kWh/ year.
Measure 2: Building Management System for air
conditioning.
Methodology: Further energy savings were achieved through
Building Management System real-time monitoring &
controlling of air-conditioning usage. Most SOEM KL facilities
are in use at all hours, but many non-production areas are not
occupied especially at night. During this time, the airconditioning could be shutdown. Another 1,966,094 kWh/ year
saving was gained from this shutdown mode.
Figure 27: Building Management System
Measure 3: Cool air leakage prevention.

Methodology: Air curtain and plastic curtain are used at building envelope openings to
keep cool air from leaking out to non-air conditioned areas. These help to reduce the load
on the centralised air conditioning system. Energy saving gained was 505,636 kWh/ year.
Measure 4: Eco Challenge projects.
Methodology: SOEM KL introduced the Eco Challenge project in FY2011 as a key
initiative to save energy within the production floors by productions members
themselves. The targeted areas were air-conditioning improvement, lighting improvement
and equipment improvement (see Figure 28).
Energy saving achieved was 172,250 kWh/ year.
Figure 28: Example of Eco Challenge activities Air-conditioning & machine improvement
Measure 5: Translucent roof installation.

Methodology: Replacement of metal roof with translucent roof at
warehouses. Translucent roof provides day lighting, saving energy by
reducing electrical lighting requirements. With these translucent roofs, 556
units of fluorescent lamp could be switched off during daytime, saving
gained of 84,548 kWh/ year.
Figure 29: Translucent roof at warehouse
Measure 6: Replacement of magnetic ballasts with electronic ballasts.

Methodology: Electronic ballasts usually supply power to the lamp at a frequency of
20,000 Hz or higher, rather than the mains frequency of 50 - 60 Hz. They have
15

approximately half the power lost of magnetic ballasts. Lamp efficacy also increases (by
approximately 10%) when the lamp operates at a frequency above 20 kHz.
Energy saving gained was 22,472 kWh/ year.
Measure 7: Delamping
Methodology: Overlighting an area is simply a waste of energy since there is little
benefit in maintaining light levels higher than the recommended levels. Delamping
involves
the
removal
of
unnecessary
lamps
to
reduce
energy
consumption while ensuring that adequate light levels are maintained. SOEM KL has
adopted the recommended lighting level at workplace from Malaysian Standard MS
1525:2007 - Code of Practice on Energy Efficiency as its illuminance standard.
Total 948 units of lamps were removed which amounted to saving of 288,314 kWh/ year.
Measure 8: LED lights Installation.
Methodology: LED light offers the potential of reducing lighting energy requirements by
76%, with additional savings being realized in reduced air-conditioning costs as LED
light with lower energy use translate into reduced cooling loads.
SOEM KL has installed 5,884 units of LED light mostly at Production areas which
operating 24 hours. Energy saving gained was 1,057,425 kWh/ year.
Measure 9: Compressed air leakage reduction.
Methodology: Air leakages are a significant source of wasted energy in a compressed air
system, sometimes wasting 20 to 30 percent of a compressors output. The leak
prevention program consists of identification, tagging, repair and verification.
Energy saving gained from this activity was 1,813,641 kWh/ year.
Measure 10: PC optimization.
Methodology: There were 321 units of PC used at production lines to
display various machines operating data. Using new IGTP server to
directly retrieve the data, 244 units of PC could be eliminated. Energy
saving gained was 64,632 kWh/ year.
Figure 30: PC optimisation at Auto Mount
Measure 11: Clean Booth Fan Filter Unit (FFU) speed reduction.
Methodology: By using inverter, FFU motor frequency had been reduced from 60Hz to
50H, thus its speed reduces while still maintaining the dust filtration requirement.
Measure 12: Compressor shut down during non-working day
Methodology: Since the compressed air demand is
lower on Sunday, one compressor could be shut down.
Figure 31: Air compressor management
16

7. Originality
______________________________________________________________________________
Measure: LCD K-Box conveyor-less system operation
Methodology: Insteads of conveyor system, SOEM KL has installed
14 new LCD K-Box lines using Yazaki pipes as the lines structure.
With this conveyor-less concept, there is no electricity required. The
concept makes future lines modification easier and cheaper for
investment too.
SOEM KL saved 237,000 kWh/ year with this
innovation. Besides this, SOEM KL managed to save RM13 million
of the installation costs for all 14 lines.
Figure 32: LCD K-Box Conveyor-less system operation
Measure: Reflow oven thermal insulation
Methodology: Reflow ovens were retro-fitted with thermal insulation to
prevent heat transfer to the surrounding area. A well insulated oven consumes
less energy through shorter initial heating time, more stable temperature and
longer duty cycle of the heating elements. Less heat generated to the ambient
air also translates to reduce load on the centralised air conditioning system.
Total energy saving gained was 839,793 kWh/ year.
Measure: Reflow oven cooling mode temperature reduction.
Methodology: Reflow ovens cooling mode temperature have been reduced
from 150oC to 50oC during weekend or non working day. Energy saving
gained was 331,200 kWh/ year.
Figure 33: Oven thermal insulation
Figure 34: Oven cooling mode temperature reduction
Measure: Local Exhaust Ventilation (LEV) optimization.

Methodology: LEV system serves to discharge the contaminated air away
from the building. However, it was found out that the exhaust of reflow ovens
had been over discharged by 40%. By adding Variable Speed Drive units to
LEV motors, the exhaust flows could be reduced to match machines
requirement. Total energy saving gained was 461,713 kWh/ year.
Figure 35: Oven LEV optimisation
Measure: BioGas generator

Instead of sending its food wastes to landfill; SOEM KL
reused parts of its food waste to generate renewable energy.
The food wastes undergo methanogenesis process to generate
methane gas, which is then used in our canteen for cooking,
replacing LPG. Besides producing renewable energy of 3,360
kg/year, this BioGas generator is also enabled SOEM KL to
reduce its generated wastes by 72 ton/year. Saving gained
through the reduction of LPG usage was about RM13,810/ year.
17
Figure 36: BioGas process flow

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ASEAN Best Practices Competition for Energy Management

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